Method of manufacturing a vehicle

ABSTRACT

A method of manufacturing a vehicle. A set of vehicle body structure components is assembled with interlocking mating features.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a method of manufacturing a vehicle.

SUMMARY OF THE INVENTION

In at least one embodiment of the present invention, a method ofmanufacturing a vehicle is provided. The method includes providing a setof cast vehicle body structure components. Each member of the set ofcast vehicle body structure components has a mating feature. Each memberof the set of cast vehicle body structure components is assembled to atleast one other member of the set by interlocking the mating features.

In at least one other embodiment of the present invention, a method ofmanufacturing a vehicle is provided. The method includes providing a setof vehicle body structure components, selecting first and second subsetsfrom the set of vehicle body structure components, assembling a floorportion by interlocking each member of the first subset to anothermember of the first subset, assembling an upper portion by engaging eachmember of the second subset to another member of the second subset, andassembling the upper portion to the floor portion.

In at least one embodiment of the present invention, a method ofmanufacturing a vehicle is provided. The method includes providing firstand second sets of castings, assembling a floor portion by interlockingthe members of the first set of castings, assembling an upper portion byinterlocking the members of the second set of castings without welding,and assembling the upper portion to the floor portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially exploded perspective view of an exemplary vehiclehaving a vehicle body assembly.

FIG. 2 is a partially exploded perspective view of the vehicle bodyassembly of FIG. 1 having a vehicle body structure.

FIG. 3 is an exploded perspective view of a portion of the vehicle bodystructure shown in FIG. 2.

FIG. 4 is an exploded perspective view of a first zone of the vehicle.

FIG. 5 is a top section view of an embodiment of the inner fenderstructure shown in FIG. 4 along section line 5-5.

FIG. 6 is a top section view of the inner fender structure of FIG. 5 inan exemplary deformed condition.

FIG. 7 is a perspective view of another embodiment of an inner fenderstructure.

FIG. 8 is a top section view of the inner fender structure of FIG. 7along section line 8-8.

FIG. 9 is a top section view of the inner fender structure of FIG. 8 inan exemplary deformed condition.

FIG. 10 is a perspective view of a first embodiment of an engine supportstructure.

FIG. 11 is a side view of an engine support structure disposed in thevehicle.

FIG. 12 is a perspective view of a second embodiment of an enginesupport structure.

FIG. 13 is an exploded perspective view of a second zone of the vehicle.

FIG. 14 is a fragmentary perspective view of a portion of a closureframe structure.

FIG. 15 is an exploded fragmentary perspective view of an interfacebetween an inner fender structure and a closure frame structure.

FIG. 16 is a fragmentary view of an embodiment of a closure hinge.

FIG. 17 is an exploded perspective view of another embodiment of aclosure hinge.

FIG. 18 is a section view of a portion of the closure hinge shown inFIG. 17.

FIGS. 19-22 are exploded perspective views of various embodiments of athird zone of the vehicle.

FIGS. 23-26 are exploded perspective views of various embodiments of afourth zone of the vehicle.

FIG. 27 is an exploded perspective view of a floor structure.

FIG. 28 is an exploded perspective view of a portion of the floorstructure shown in FIG. 27.

FIGS. 29-36 are various embodiments of mating features that may beprovided with vehicle body structure components.

FIGS. 37A-37D are side views of various vehicle configurations.

FIGS. 38 and 39 are perspective views of exemplary body panels.

FIGS. 40 and 41 are fragmentary perspective views of hinge coverportions of a body panel.

FIGS. 42-46 are exemplary embodiments of connections between body panelsand the vehicle body structure.

DETAILED DESCRIPTION

Detailed embodiments of the present invention are disclosed herein;however, it is to be understood that the disclosed embodiments aremerely exemplary of the invention that may be embodied in various andalternative forms. The figures are not necessarily to scale, somefeatures may be exaggerated or minimized to show details of particularcomponents. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for the claims and/or as a representative basis forteaching one skilled in the art to variously employ the presentinvention.

Referring to FIGS. 1 and 2, an exemplary vehicle 10 is shown. Thevehicle 10 may be of any suitable type, such as a motor vehicle like anautomobile. For clarity, the vehicle 10 is shown without selectcomponents, such as wheels, tires, and drivetrain components.

The vehicle 10 may include a vehicle body assembly 12 having a vehiclebody structure 14 and a plurality of body panels 16. For illustrationpurposes, at least a portion of the body panels 16 are fragmented orremoved in FIG. 2 to better show the vehicle body structure 14.

The vehicle body assembly 12 and vehicle body structure 14 may includean upper portion 18 and a lower portion 20. The upper portion 18 maydefine at least a portion of an engine compartment 22 and at least aportion of a passenger compartment 24. In the embodiment shown, theengine compartment 22 is disposed proximate the front of the vehicle 10;however, the engine compartment 22 may be disposed in any suitablelocation, such as toward the rear of the vehicle 10. The body panels 16may be disposed on the upper portion 18 as will be described in moredetail below. In addition, one or more closures, such as a door, hood,liftgate, tailgate, trunk lid, hatchback, or the like, may be moveablydisposed on the upper portion 18.

The lower portion 20 may generally be disposed under the upper portion18 and may also define at least a portion of the engine compartment 22and/or the passenger compartment 24. The lower portion 20 may at leastpartially define a floor assembly in one or more embodiments of thepresent invention as will be discussed in more detail below.

Referring to FIG. 3, an exploded view of the vehicle body structure 14is shown. For clarity, closure structures associated with the passengercompartment 24 are not shown to better illustrate other components ofthe vehicle body structure 14.

The vehicle body structure 14 may be made up of a set of components. Amember of the set of body structure components may interlock with atleast one another member of the set when the vehicle body structure 14is assembled. The interlocking members of the set may have differentconfigurations and may include one or more types of mating features aswill be described in more detail below.

In at least one embodiment, at least some of the members of the set ofbody structure components may be provided as castings and may beprovided with integral mating features. For example, the integral matingfeatures may be cast as part of an associated body structure component,thereby providing a one-piece construction. In addition, members of theset of body structure components may be made of any suitable material.For example, at least some of the members of the set of body structurecomponents may be made of a magnesium alloy to provide desirablestrength, weight, and manufacturability characteristics.

The vehicle 10, vehicle body assembly 12, and/or vehicle body structure14 may include a plurality of zones. Each zone may include a subset ofthe set of body structure components and may include one or morecomponents that are part of the upper and lower portions 18,20. Forexample, the vehicle body structure 14 may include a first zone 30disposed proximate a front end of the vehicle 10, a second zone 32 thatmay be disposed adjacent to the first zone 30, a third zone 34 that maybe disposed adjacent to the second zone 32, and a fourth zone 36 thatmay be disposed adjacent to the third zone 34 and proximate a rear endof the vehicle 10.

Referring to FIG. 4, an exploded view of an exemplary first zone 30 ofthe vehicle 10 is shown. For clarity, the first zone 30 is shown withoutbody panels to more clearly depict the underlying portion of the vehiclebody structure 14. The first zone 30 may at least partially define theengine compartment 22 of the vehicle 10 and may include a hood closurestructure 100, a front end structure 102, a first inner fender structure104, a second inner fender structure 106, and an engine supportstructure 108.

The hood closure structure 100 may be pivotally attached to anothervehicle body structure component to cover or provide access to theengine compartment 22. The hood closure structure 100 may include aplurality of ribs 110 that provide structural reinforcement and aplurality of openings 112 to reduce weight and material usage. In atleast one embodiment, the hood closure structure 100 may be a casting.In addition, one or more body panels may be disposed proximate the hoodclosure structure 100 to at least partially conceal the hood closurestructure 100 and provide an exterior vehicle surface.

The front end structure 102 may be provided proximate the front end ofthe vehicle 10. In at least one embodiment, the front end structure 102may extend across the front end of the vehicle 10 and may include one ormore airflow openings 114 that permit airflow toward the enginecompartment 22. In addition, the front end structure 102 may includeopenings for receiving other vehicle components, such as lights orlatches, and may receive a front end bumper structure and/or body panel.

The front end structure 102 may include mating features for engaginganother vehicle body structure component. For example, as is best shownin FIG. 3 the front end structure 102 may include first and second frontend mating features 116,118 that engage or interlock with the first andsecond inner fender structures 104,106, respectively. In one or moreembodiments of the present invention, one or more fasteners may be usedto couple the front end structure 102 to the first and second innerfender structures 104,106.

The first and second inner fender structures 104,106 may be configuredto absorb energy during a vehicle impact event to help protect a vehicleoccupant. For instance, the inner fender structures 104,106 may beconfigured to distort (e.g., fold, buckle, collapse, or otherwise changeshape) when sufficient force is transmitted to an inner fenderstructure.

The first and second inner fender structures 104,106 may be spaced apartfrom each other and disposed along opposite sides of the vehicle 10. Inthe embodiment shown in FIG. 4, the first and second inner fenderstructures 104,106 are generally configured as mirror images of eachother. For simplicity, only the first inner fender structure 104 will bedescribed in detail below with the understanding that the second innerfender structure 106 may have similar attributes.

The inner fender structure 104 may include a body 120 having a mountingportion 122 and an arm portion 124 that extends from the mountingportion 122. The body 120 may be provided such that the mounting and armportions 122,124 are integrally formed as a one-piece component.

The mounting portion 122 may be adapted to mount to another vehicle bodystructure component as will be described in more detail below. In atleast one embodiment, the mounting portion 122 may include a matingfeature 126 configured as a mortise.

The arm portion 124 may extend from the mounting portion 122 toward thefront of the vehicle 10. The arm portion 122 may have a distal end 128spaced apart from the mounting portion 122. The distal end 128 mayengage or interlock with the front end structure 102. In addition, oneor more mating features 130 may be associated with the distal end 128.The distal end 128 and/or the mating features 130 may have a maleconfiguration, female configuration, or combinations thereof. The armportion may be disposed toward an upper surface of the vehicle 10 tohelp counter “vaulting” or lifting of the rear wheels from the groundand to help occupants remain in a location where one or more occupantprotection devices may be effective during a vehicle impact event.

Referring to FIGS. 4 and 5, one embodiment of an arm portion 124 isshown in more detail. The arm portion 124 may include a plurality ofpockets 132. Each pocket 132 may include at least one opening 134. Theopenings 134 of adjacent pockets may be disposed along opposite sides ofthe arm portion 124. As such, the arm portion 124 may be configured todistort in a preconfigured manner when sufficient force is transmittedto the arm portion 124. In addition, at least one reinforcement feature136 may partially fill one or more pockets 132 to help maintain a pocketconfiguration under ordinary conditions.

Referring to FIG. 5, a cross section of the arm portion 124 of the innerfender structure 104 is shown. The inner fender structure 104 and/or armportion 124 may include one or more walls that help define one or morepockets 132. For example, the inner fender structure 104 may include aserpentine wall 140 that at least partially defines one or more pockets132. As such, one or more portions of the serpentine wall 140 mayseparate adjacent pockets 132. The pockets 132 may have any suitableconfiguration. In at least one embodiment, the pockets 132 may increasein size in a direction extending from the distal end 128 toward themounting portion 122. Moreover, at least a portion of the serpentinewall 140 may be stronger than one or more other walls to help direct orrespond to load forces in a desired manner.

A back wall 142 may be disposed opposite one or more openings 134. Inthe embodiment shown in FIG. 5, the back wall 142 is provided as part ofthe serpentine wall 140.

First and second longitudinal walls 144,146 may also at least partiallydefine one or more pockets 132. In at least one embodiment, the firstand second longitudinal walls 144,146 may be spaced apart from eachother and extend from the mounting portion 122. In addition, the firstand second longitudinal walls 144,146 may be disposed proximate theserpentine wall 140 and/or back wall 142.

One or more pre-weakened areas 148 may be provided that influence theload bearing characteristics of the arm portion 124. A pre-weakened area148 may be provided that at least partially extends through one or morewalls. For instance, a plurality of pre-weakened areas 148 may beprovided in the first and second longitudinal walls 144,146 proximatethe serpentine wall 140 and/or an opening 134.

At least some of the walls 140,142,144,146 and pockets 132 may distortwhen sufficient force is applied. Moreover, the walls 140,142,144,146and pockets 132 may be configured to withstand different load forces orabsorb different amounts of energy. For example, one or more wallsand/or pockets may be distorted or change shape under lower load forcesthan other walls, portions of walls, and/or pockets. In at least oneembodiment, the arm portion 124 may be configured to withstand higherload forces closer to the mounting portion 122 than the distal end 128.Moreover, the arm portion 124 may generally be configured to deformprior to deformation of the mounting portion 122.

Referring to FIG. 6, the arm portion 124 of the inner fender structure104 is shown in an exemplary deformed condition. Deformation may resultin a reduction in length of the arm portion 124 due to reduced size orvolume of one or more pockets 132. The arm portion 124 may be configuredto deform in a predetermined manner. For instance, one or more walls maydeform such that a pocket 132 collapses or folds in a predetermineddirection. In FIG. 6, a plurality of partially collapsed pockets 132 isshown such that the serpentine wall 140 and partially collapsed pocketsare partially folded toward an associated opening 132.

Referring to FIGS. 7 and 8, another embodiment of an inner fenderstructure 150 is shown. The inner fender structure 150 may include abody 152 having a mounting portion 154 and an arm portion 156 thatextends from the mounting portion 154. The body 152 may be provided suchthat the mounting and arm portions 154,156 are integrally formed as aone-piece component. The inner fender structure 150 may also include atunable member 158, a first end plate 160, and a second end plate 162.

The mounting portion 154 may be adapted to mount to another vehicle bodystructure component as will be described in more detail below. Themounting portion 154 may have a similar configuration as described abovewith respect to inner fender structure 104.

The arm portion 156 may include a first panel 164, a second panel 166,and a set of web panels 168. The first and second panels 164,166 mayextend from the mounting portion 154 and may be generally symmetricaland spaced apart from each other. The first and second panels 164,166may have a configuration that helps the arm portion 156 distort in apredetermined manner as will be described in more detail below.

The web panels 168 may extend between the first and second panels164,166. In the embodiment shown, the web panels 168 are disposed in acorrugated arrangement such that adjacent web panels 168 are disposed atan angle relative to each other. Each web panel 168 may intersect or bespaced apart from another web panel. In addition, one or more web panels168 may be disposed generally perpendicular to at least one of the firstand second panels 164,166.

One or more of the web panels 168 may include an aperture 170. Theapertures 170 may be arranged along an axis 172.

The tunable member 158 may affect the energy absorption characteristicsof the inner fender structure 150. The tunable member 158 may have anysuitable configuration. In the embodiment shown, the tunable member 158is configured as a tubular channel. The tunable member 158 may extendthrough the apertures 170 and may be made of any suitable material, suchas a metal like steel. A separator, such as a coating or spacer, may beprovided between the tunable member 158 and one or more apertures 170 toinhibit galvanic corrosion in one or more embodiments of the presentinvention.

The tunable member 158 may include one or more pre-weakened areas 174.The pre-weakened areas 174 may be provided in any suitable manner. Forexample, the pre-weakened areas 174 may be provided as a plurality ofindentations or holes that may be spaced apart from each other and mayextend at least partially through the tunable member 158. For example,the pre-weakened areas 174 may be spaced apart from each other in one ormore directions, such as in a direction extending along axis 172. Thepre-weakened areas 174 may “tune” or configure the tunable member 158 todistort in a predetermined manner when sufficient force is applied aswill be discussed in more detail below. As such, different tunablemembers may be employed to provide different response characteristicsfor application in different vehicle packages. In addition, the tunablemember 158 may be configured such that different areas deform atdifferent load thresholds.

The first and second end plates 160,162 may be adapted to constrain thetunable member 158. The first end plate 160 may be disposed proximate adistal end of the arm portion 156 and proximate a first end of thetunable member 158. The second end plate 162 may be provided at a secondend of the tunable member 158 disposed opposite the first end. The firstand second end plates 160,162 may be made of any suitable material, suchas a metal like steel, and may be adapted to withstand load forcesassociated with a vehicle impact event. In addition, the first andsecond end plates 160,162 may be coupled to the inner fender structure150 in any suitable manner, such as with one or more fasteners or byinsertion into an opening. For instance, the second end plate 162 may bereceived in an opening or pocket disposed proximate the mounting portion154 as shown with hidden lines in FIG. 7.

Referring to FIG. 9, an inner fender structure 150 is shown in anexemplary deformed condition. Deformation of the arm portion 156 may befacilitated when the tunable member 158 is deformed and may be inhibitedwhen the tunable member 158 is not deformed. As such, the arm portion156 and tunable member 158 may cooperate to absorb energy. Deformationof the tunable member 158 may be affected by its strengthcharacteristics. For example, the tunable member 158 may have lowerdistortion resistance proximate a pre-weakened area 174.

The arm portion 156 may be configured to deform in a predeterminedmanner. For example, the first and second panels 164,166 and web panels168 may cooperate with the tunable member 158 to fold back and forthwhen sufficient force is applied. As such, one or more web panels 168may be configured to distort or fold relative to another web panel whenan associated area of the tunable member 156 is deformed.

Referring to FIG. 10, one embodiment of an engine support structure 108is shown. The engine support structure 108 may include a first framerail 180, a second frame rail 182, and a cradle 184.

The first and second frame rails 180,182 may extend from at least onevehicle body structure component. In at least one embodiment, the firstand second frame rails 180,182 may be spaced apart and extend generallyparallel to each other. In addition, the first and second frame rails180,182 may at least partially define a tunnel or passage 186 into whichvarious components, such as a transmission, drive shaft, or conduits mayextend.

The first and second frame rails 180,182 may have similarconfigurations. For instance, the first and second frame rails 180,182may have the same configuration or may be configured as mirror images ofeach other. For brevity, the first frame rail 180 will be described indetail below with the understanding that the second frame rail 182 mayhave similar attributes.

The first frame rail 180 may have a first end portion 190 and a secondend portion 192 disposed opposite the first end portion. The first endportion 190 may be mounted to a portion of the vehicle body structure inany suitable manner, such as with interlocking mating features and/orfasteners. In addition, the first end portion 190 may include aplurality of branches, such as first and second branches 194,196. Thefirst and second branches 194,196 may be spaced apart and may helpreinforce a portion of the vehicle body structure. For instance, atleast one of the first and second branches 194,196 may extend betweenmultiple zones as shown in FIG. 3 in one or more embodiments of thepresent invention.

The second end portion 192 may extend into the engine compartment 22.The second end portion 192 may engage another vehicle body structurecomponent, such as the front end structure 102 as represented in FIG. 2,or may be spaced apart from the front end structure 102 in a cantileverarrangement as is represented in FIG. 4.

The cradle 184 may be disposed on the first and second frame rails180,182. In the embodiment shown in FIG. 10, the cradle 184 includesfirst and second sets of apertures 200,202 disposed proximate oppositesides of the cradle 184 that receive the first and second frame rails180,182, respectively. The members of the sets of apertures may have anysuitable configuration, such as holes or open sided slots as is shown inFIG. 10.

The cradle 184 may also include first and second side portions 204,206that generally extend above and/or between the members of the first andsecond sets of apertures 200,202, respectively. A bridge 208 may extendbetween the first and second side portions 204,206. The bridge 208and/or first and second side portions 204,206 may cooperate to supportan engine 210, as shown in phantom in FIG. 11. In addition, the firstand second side portions 204,206 may be attached to opposing first andsecond inner fender structures to provide additional structural support.In addition, the cradle 184 may be configured to receive or support asteering system component 212, such as a shaft or steering gear. Likeother vehicle body structure components, the cradle 184 may be providedas a one piece casting. In the embodiment shown, the steering systemcomponent is generally disposed toward the front of the cradle; however,invention also contemplates that a steering system component may bedisposed in any suitable location such as toward the rear side of thecradle.

Referring to FIG. 12, another embodiment of an engine support structure220 is shown. The engine support structure may include first and secondframe rails 222,224 and a cradle 226.

The first and second frame rails 222,224 may include a plurality ofexterior surfaces 228 and a plurality of pre-weakened areas 230. Thepre-weakened areas 230 may be provided in any suitable manner. Forexample, the pre-weakened areas 230 may be provided as a plurality ofindentations or holes that may be spaced apart from each other and mayextend at least partially through the frame rails 222,224. For example,the pre-weakened areas 230 may be spaced between the ends of each framerail 222,224. The pre-weakened areas 230 may configure the frame rails222,224 to distort in a predetermined manner when sufficient force isapplied as will be discussed in more detail below. In addition, theframe rails 222,224 may be configured such that different areas deformat different load thresholds.

The cradle 226 may have similar features as the cradle 184 shown in FIG.10. In the embodiment shown in FIG. 12, the cradle 226 has apertures 232configured as through holes. In addition, one or more surfaces of theaperture 232 may mate with a frame rail to help position the cradle 226.

The engine support structures 108,220 described above may help protect avehicle occupant during a vehicle impact event. The frame rails maydistort between the cradle and frame rail end portions to absorb impactenergy. In addition, the frame rails 222,224 may have increasingresistance to deformation and/or axial strength in the directionextending from the second end toward the first end to provide desireddeformation characteristics. In at least one embodiment, the frame railsmay distort between the cradle apertures in an area generally underneathan engine, thereby providing increased area or distance for absorbingenergy.

Referring to FIGS. 13 and 14 an exemplary second zone 32 is shown. Forclarity, the second zone 32 is shown without body panels to more clearlydepict the underlying portion of the vehicle body structure 14. Thesecond zone 32 may at least partially define a passenger compartment 24of the vehicle 10, such as a front portion disposed proximate the firstzone 30. The second zone 32 may include a roof structure 250, a cowlstructure 252, a first floor structure 254, a first closure framestructure 256, a second closure frame structure 258, a first closurestructure 260, and a second closure structure 262.

The roof structure 250 may at least partially define a roof of thevehicle 10. For example, the roof structure 250 may extend between thefirst and second closure structures 256,258. The roof structure 250 mayreceive one or more body panels and may include a sunroof or moonroofopening in one or more embodiments of the present invention.

The roof structure 250 may include a plurality of mating features thatengage or interlock with another vehicle body structure component. Forinstance, the roof structure 250 may include first and second sets ofroof mating features 270,272 that engage or interlock with the first andsecond closure structures 256,258, respectively. The first and secondsets of roof mating features 270,272 may be disposed on a surface of theroof structure 250 that faces the passenger compartment 24. The roofstructure 250 may also include a third set of roof mating features 274that engage or interlock with a vehicle body structure componentdisposed in an adjacent zone, such as the third zone 34. In at least oneembodiment, the third set of roof mating features 274 may be disposedalong a rear surface of the roof structure 250. The mating features270,272,274 may have any suitable configuration as will be discussed inmore detail below.

The cowl structure 252 may at least partially separate the enginecompartment 22 from the passenger compartment 24. The cowl structure 252may be disposed between the first and second closure frame structures256,258 and may be configured to receive an instrument panel and carrystructural loads.

The cowl structure 252 may include various mating features that engageor interlock with another vehicle body structure component. In at leastone embodiment, the cowl structure 252 may include first and second endmating features 280,282 that engage or interlock with the first andsecond closure frame structures 256,258, respectively. The cowlstructure 252 may also include mating features that engage or interlockwith the first floor structure 254. For instance, the cowl structure 252may include a mating region 284 that engages the first floor structure254. The mating region 284 may have any suitable configuration and mayoverlap or include male and/or female features, like a tongue and groovearrangement, to inhibit leakage of fluids or gases. The cowl structure252 may include elongated portions that extend downwardly to engage thefirst floor structure 254. The elongated portions may be generallydisposed in front of left and right occupant seating positions and maybe generally symmetrical to accommodate left and right hand driveconfigurations in which the driver is positioned in left or right sideseating positions, respectively.

The first floor structure 254 may at least partially define a floor ofthe passenger compartment 24. The first floor structure 254 may bedisposed proximate or may be mounted to the first and second closurestructures 256,258 and the cowl structure 252. Additional features ofthe first floor structure 254 and other lower portion 20 components willbe discussed in more detail below.

The first and second closure frame structures 256,258 may be disposed onopposite sides of the vehicle 10. Each closure frame structure 256,258may at least partially define an opening that receives a closurestructure. In the embodiment shown, the first and second closure framestructures 256,258 each extend around and define openings that mayreceive a closure structure.

The first and second closure frame structures 256,258 may includevarious features for mating with other vehicle body structurecomponents. For example, the first and second closure frame structures256,258 may each include an upper mating feature 290, a structure matingfeature 292, a cowl mating feature 294, an inner fender mating feature296, and a hinge portion 298. These mating features may be integrallyformed with their respective closure frame structures.

The upper mating features 290 of the first and second closure framestructures 256,258 may engage or interlock with the first and secondroof mating features 270,272, respectively. The upper mating features290 may have any suitable configuration that is compatible with thefirst and second roof mating features 270,272.

At least one structure mating feature 292 may be provided that engagesor interlocks with a vehicle body structure component disposed in anadjacent zone, such as the third zone 34. In at least one embodiment,the structure mating features 292 may be disposed along a rear surfaceof the closure frame structures 256,258 and may have any suitableconfiguration as will be discussed in more detail below.

The cowl mating features 294 of the first and second closure framestructures 256,258 may engage or interlock with the first and second endmating features 280,282, respectively. Each cowl mating feature 294 maybe disposed on a side of a closure frame structure that is disposedbetween the inner fender mating feature 296 and hinge portion 298. Thecowl mating features 294 may also receive a portion of an instrumentpanel in one or more embodiments of the present invention.

Referring to FIGS. 13 and 14, the inner fender mating features 296 mayextend from and be integrally formed with the closure frame structures256,258. In at least one embodiment, an inner fender mating feature 296may be disposed along a front surface 300 between an A pillar 302 and abottom surface 304 of each closure frame structure 256,258. The innerfender mating features 296 may be configured as a tenon that may have agenerally rectangular configuration and may extend across the frontsurface 300 to distribute load forces. At least one sleeve 306 may beprovided for receiving a fastener. In addition, a reinforcing rib 308may extend between one or more sleeves 306 to provide increased strengthand distribute load forces. Optionally, the A pillar 302 may be providedwith one or more through holes or openings 312 that provide visibilityfor a vehicle occupant by reducing visual obstructions.

Referring to FIG. 15, an exemplary connection between a closure framestructure and an inner fender structure is shown. Such a connection maybe made without welding the closure frame structure to the inner fenderstructure. In the embodiment shown, a mating feature 126 configured as amortise is provided with an inner fender structure and is configured toreceive an inner fender mating feature 296 configured as a tenon. Such aconfiguration may provide a stable mounting configuration and maywithstand high load forces, such as may be associated with a vehicleimpact event. One or more fasteners may extend at least partiallythrough the mating features 126,296 to further couple the inner fenderstructure and closure frame structure.

Other surfaces of the inner fender structure and closure frame structuremay cooperate to help distribute load forces. For instance, the frontsurface 300 of the closure frame structure and back surface 310 of theinner fender structure may be disposed adjacent to each other andtransfer load forces from the inner fender structure to the closureframe structure. Moreover, the front and back surfaces 300,310 may notbe directly attached or welded to each other to facilitate removal orreplacement of the inner fender structure. In at least one alternateembodiment, one or more additional fasteners may be located below thearm portion to further couple the inner fender structure to a closureframe structure.

Referring again to FIGS. 13 and 14, the first and second closurestructures 260,262 may be pivotally disposed on the first and secondclosure frame structures 256,258, respectively. In at least oneembodiment, the closure structures 260,262 may each include a closurehinge portion 320.

The closure frame hinge portions 298 and closure hinge portions 320 mayhave any suitable configuration. In the embodiment shown in FIGS. 13 and14, the hinge portions 298,320 may be generally aligned with each other.Each hinge portion 298,320 may have an upper wall 322, a lower wall 324,and at least one side wall 326 that may cooperate to define a pocket328. The upper and lower walls 322,324 may each have a hole 330. Theholes 330 may generally be disposed along an axis. In at least one otherembodiment, such as that shown in FIG. 16, closure frame and closurehinge portions 298′,320′ may have a single wall that includes a hole330′.

Referring to FIGS. 17 and 18, an exemplary connection between the hingeportions 298,320 is shown. The connection may include various componentsthat permit the hinge portions 298,320 to receive a hinge pin 340 andpermit a closure structure to pivot with respect to a closure framestructure without binding. In FIG. 18, the hinge pin 340 is not shownfor clarity. In addition to the hinge pin 340 the hinge portionconnection components may include a first bushing 342, a second bushing344, a shim 346, and a cover 348.

The first bushing 342 may be received by at least one hole 330. Thefirst bushing 342 may include a body portion 350 and a flange portion352 disposed proximate the body portion 350. The body portion 350 mayhave any suitable configuration. In the embodiment shown, the bodyportion 350 is generally cylindrical and includes a through hole 354that may receive the hinge pin 340. The flange portion 352 may extendoutwardly and may help position the first bushing 342 with respect to ahinge portion. The flange portion 352 may include a recess 356 that atleast partially receives at least one other connection component as willbe described in more detail below. In addition, the body and/or flangeportions 350,352 may be disposed about a bushing axis 358.

The second bushing 344 may have a similar configuration as the firstbushing 342. The second bushing 344 may include a body portion 360 and aflange portion 362. The body portion 360 may include a through hole 364that receives the hinge pin 340. The flange portion 362 may engage thefirst bushing 342. In at least one embodiment, the flange portion 362may be at least partially received in the recess 356.

The shim 346 may be disposed between the first and second bushings342,344. In at least one embodiment, the shim 346 may be disposed in therecess 356 and may include a through hole 370. The through hole 370 maybe disposed about a hole axis 372 that may be offset from the center ofthe shim 346 and may be offset from the bushing axis 358. In addition,the shim 346 may include a notch 374 that receives the flange portion362 of the second bushing 344 as is best shown in FIG. 18. The throughhole 370 may receive the second bushing 344 while a perimeter surface376 of the shim 346 may engage the flange portion 352 or recess wall ofthe first bushing 342. As such, the shim 346 may facilitate alignment ofthe first and second bushings 342,344. For example, the shim 346 may berotated with respect to the first bushing 342 to adjust the position ofthe second bushing 344, thereby helping to align the bushings 342,344and accommodate misalignment of the holes 330. Shims may be provided inone or more sizes (e.g., thicknesses and/or through hole locations) toaccommodate different adjustment needs.

The cover 348 may be disposed proximate the first bushing 342 and mayhelp hold the second bushing 344 and/or shim 346 adjacent to the firstbushing 342. The cover 348 may have any suitable configuration. Forexample, the cover 348 may include a hook and loop fastener thatfacilitates attachment to the first bushing 342 and may accommodaterotation of the shim 346 and repositioning of the second bushing 344.

Referring to FIGS. 19-22 various embodiments of exemplary third zones 34are shown. These embodiments may at least partially define a passengercompartment 24 of the vehicle 10, such as an intermediate or rearportion disposed adjacent to the second zone 32.

Referring to FIG. 19, a first embodiment of a third zone 34 is shown.This embodiment may be representative of a four door vehicleconfiguration. The third zone 34 may include a roof structure 400, asecond floor structure 402, a first closure frame structure 404, asecond closure frame structure 406, a first closure structure 408, and asecond closure structure 410.

The roof structure 400 may at least partially define a roof of thevehicle 10. For example, the roof structure 400 may extend between thefirst and second closure structures 404,406. The roof structure 400 mayreceive one or more body panels and may include a sunroof or moonroofopening in one or more embodiments of the present invention.

The roof structure 400 may include a plurality of mating features thatengage or interlock with another vehicle body structure component. Forinstance, the roof structure 400 may include first and second sets ofroof mating features 420,422 that engage or interlock with the first andsecond closure structures 404,406, respectively. The first and secondsets of roof mating features may be disposed on a surface of the roofstructure 400 that faces the passenger compartment 24. The roofstructure 400 may also include a third and fourth sets of roof matingfeatures 424,426 that engage or interlock with a vehicle body structurecomponent disposed in an adjacent zone, such as the second and fourthzones 32,36, respectively. In at least one embodiment, the third andfourth sets of roof mating features 424,426 may be disposed along afront and rear surfaces of the roof structure 400, respectively. Themating features 420,422,424,426 may have any suitable configuration aswill be discussed in more detail below.

The second floor structure 402 may at least partially define a floor ofthe passenger compartment 24. The second floor structure 402 may bedisposed proximate or may be mounted to the first and second closurestructures 404,406. Additional features of the second floor structure402 and other lower portion 20 components will be discussed in moredetail below.

The first and second closure frame structures 404,406 may be disposed onopposite sides of the vehicle 10. Each closure frame structure 404,406may at least partially define an opening that receives a closurestructure. The first and second closure frame structures 404,406 mayinclude various features for mating with other vehicle body structurecomponents. For example, the first and second closure frame structures404,406 may each include hinge portions 298, an upper mating feature430, and first and second structure mating features 432,434. Thesemating features may be integrally formed with their respective closureframe structures in one or more embodiments of the present invention.

The upper mating features 430 of the first and second closure framestructures 404,406 may engage or interlock with the first and secondroof mating features 420,422, respectively. The upper mating features430 may have any suitable configuration that is compatible with thefirst and second roof mating features 420,422.

The first and second structure mating features 432,434 may engage orinterlock with vehicle body structure components disposed in adjacentzones, such as the second and fourth zones 32,36, respectively. In atleast one embodiment, the structure mating features 432,434 may bedisposed along front and rear surfaces of the closure frame structures404,406, respectively, and may have any suitable configuration as willbe discussed in more detail below.

The first and second closure structures 408,410 may be pivotallydisposed on the first and second closure frame structures 404,406,respectively. The closure structures 408,410 may have a configurationsimilar to closure structures 260 and 262. As such, each closurestructure 408,410 may each include a closure hinge portion 320 aspreviously described.

Referring to FIG. 20, a second embodiment of a third zone is shown. Thisembodiment may be representative of a regular cab pickup configurationand may include a rear structure 440 that may include a plurality ofmating features 442 that engage vehicle body structure componentsassociated with the second zone 32. In at least one embodiment, themating features 442 may face toward the front of the vehicle forengaging the roof structure 250 and first and second closure framestructures 256,258 of the second zone 32. For example, one or moremating features 442 may engage or interlock with third set of roofmating features 274 and the structure mating features 292. In addition,one or more mating features 442 may be adapted to engage part of thelower portion 20, such as the first floor structure 254 in one or moreembodiments of the present invention. In FIG. 20, the second floorstructure 402 is not shown for clarity.

Referring to FIG. 21, a third embodiment of a third zone is shown. Thisembodiment may be representative of an extended cab pickup configurationhaving at least one closure. The third embodiment may be provided bycombining the roof structure 400, a second floor structure 402, andcomponents similar to the closure frame structures 404,406, and closurestructures 408,410 with the rear structure 440 of FIG. 20. For example,the rear structure mating features 442 may engage or interlock with thefourth set of roof mating features 426 and structure mating features434. In FIG. 21, the second floor structure 402 is not shown forclarity.

Referring to FIG. 22, a fourth embodiment of a third zone is shown. Thisembodiment may be representative of an extended cab pickupconfiguration. The fourth embodiment may be provided by combining a roofstructure 400′, a second floor structure 402, and side frame structures404′,406′ with the rear structure 440. In FIG. 22, the second floorstructure 402 is not shown for clarity. At least one of the side framestructures 404′,406′ may not include a closure opening in one or moreembodiments of the present invention.

Referring to FIGS. 23-26 various embodiments of exemplary fourth zones36 are shown. These embodiments may at least partially define a rearportion of the vehicle 10.

Referring to FIG. 23, a first embodiment of a fourth zone 36 is shown.This embodiment may be representative of a van, sport utility, orhatchback vehicle configuration. The fourth zone 36 may include a roofstructure 500, a third floor structure 502, a first side structure 504,a second side structure 506, a rear structure 508, and a rear closurestructure 510.

The roof structure 500 may at least partially define a roof of thevehicle 10 and may extend between the first and second side structures502,504. The roof structure 500 may include a plurality of matingfeatures that engage or interlock with another vehicle body structurecomponent. For instance, the roof structure 500 may include first andsecond sets of roof mating features 520,522 that engage or interlockwith the first and second side structures 504,506, respectively. Theroof structure 500 may also include a third and fourth sets of roofmating features 524,526 that engage or interlock with a vehicle bodystructure component. In at least one embodiment, the third and fourthsets of roof mating features 524,526 may be disposed along a front andrear surfaces of the roof structure 500, respectively. The matingfeatures 520,522,524,526 may have any suitable configuration as will bediscussed in more detail below.

The third floor structure 502 may be disposed proximate variousstructural components, such as the first and second closure structures504,506 and/or the rear structure 508. Additional features of the thirdfloor structure 502 will be discussed in more detail below.

The first and second side structures 504,506 may be disposed on oppositesides of the vehicle 10. Each side structure 504,506 may be providedwith or without window openings. The first and second side structures504,506 may include various features for mating with other vehicle bodystructure components. For example, the first and second side structures504,506 may each include an upper mating feature 530 and first andsecond structure mating features 532,534. These mating features may beintegrally formed with the side structures.

The upper mating features 530 of the first and second side structures504,506 may engage or interlock with the first and second roof matingfeatures 520,522, respectively. The upper mating features 530 may haveany suitable configuration that is compatible with the first and secondroof mating features 520,522. These mating features may be integrallyformed with the side structures.

The first and second structure mating features 532,534 may engage orinterlock with a vehicle body structure component. These mating featuresmay be integrally formed with the side structures. In at least oneembodiment, the structure mating features 532,534 may be disposed alongfront and rear surfaces of the side structures 520,522, respectively,and may have any suitable configuration as will be discussed in moredetail below.

The rear structure 508 may include various features for mating withother vehicle body structure components. For example, the rear structure508 may include mating features 540 that engage or interlock with thefourth set of roof mating features 526 and/or structure mating features534. In addition, the rear structure 508 may also include matingfeatures that engage or interlock with the third floor structure 502.The rear structure 508 may also include hinge portions 298 thatfacilitate pivotal attachment of the rear closure structure 510. Thehinge portions 298 may be disposed proximate any side of an opening 542provided in the rear structure 508 to accommodate various closurestructure configurations and/or pivotal window attachments.

The rear closure structure 510 may be pivotally disposed on the rearstructure 508. The rear closure structure 510 may have any suitableconfiguration, such as a liftgate or one or more doors. In at least oneembodiment, the rear closure structure 510 may include a closure hingeportion 320.

Referring to FIG. 24, a second embodiment of a fourth zone is shown.This embodiment may be representative of a sedan configuration and mayinclude an upper structure 550, a first rear side structure 552, asecond rear side structure 554, and a rear closure structure 556. Thisembodiment may also include the third floor structure 502, which is notshown for clarity.

The upper structure 550 may be provided proximate upper and/or rearsurfaces of the vehicle 10. The upper structure 550 may include variousfeatures for mating with other vehicle body structure components. Forexample, the upper structure 550 may include first, second, and thirdsets of frontal mating features 560,562,564. In at least one embodiment,the first set of frontal mating features 564 may interlock with thefourth set of roof mating features 426. In addition, the upper structure550 may include one or more hinge portions 298 disposed proximate anopening 566 to facilitate pivotal mounting of the rear closure structure556.

The first and second rear side structures 552,554 may be disposed onopposite sides of the vehicle 10. The first and second rear sidestructures 552,554 may include various features for mating with othervehicle body structure components. For example, the first and secondside structures 552,554 may each include first and second sets of uppermating features 570,572 and a set of passenger compartment matingfeatures 574. These mating features may be integrally formed with theside structures.

The first and second sets of upper mating features 570,572 may engage orinterlock with the first and second sets of frontal mating features560,562, respectively. The upper mating features 570,572 may have anysuitable configuration that is compatible with the first and secondfrontal mating features 560,562. In at least one embodiment, the firstand second sets of upper mating features 570,572 may generally bedisposed along upper surfaces of the first and second side structures552,554.

The passenger compartment mating features 574 may engage or interlockwith a vehicle body structure component. In at least one embodiment, thepassenger compartment mating features 574 may be disposed along frontsurfaces of the first and second side structures 552,554 and mayinterlock with structure mating features 434. The passenger compartmentmating features 574 may have any suitable configuration as will bediscussed in more detail below.

The rear closure structure 556 may be pivotally disposed on the upperstructure 550. The rear closure structure 556 may have any suitableconfiguration, such as a trunk lid. In at least one embodiment, the rearclosure structure 556 may include a closure hinge portion 320 and ahinge connection as previously described.

Referring to FIG. 25, a third embodiment of a fourth zone is shown. Thisembodiment may be representative of a hatchback configuration and mayinclude an upper structure 580 and a rear closure structure 582. Thisembodiment may also include the third floor structure 502, which is notshown for clarity.

The upper structure 580 may include various features for mating withother vehicle body structure components. For example, the upperstructure 580 may include first, second, and third sets of frontalmating features 560′,562′,564′. In at least one embodiment, the firstand second sets of frontal mating features 560′,562′ may engage orinterlock with the first and second sets of upper mating features570,572 while the third set of frontal mating features 564′ mayinterlock with the fourth set of roof mating features 426. In addition,the upper structure 580 may include one or more hinge portions 298disposed proximate an opening 566′ to facilitate pivotal mounting of therear closure structure 582.

The rear closure structure 582 may be pivotally disposed on the upperstructure 580. The rear closure structure 582 may have any suitableconfiguration, such as a hatchback lid. In at least one embodiment, therear closure structure 582 may include a closure hinge portion 320 and ahinge connection as previously described.

Referring to FIG. 26, a fourth embodiment of a fourth zone is shown.This embodiment may be representative of a pickup truck configurationand may include the third floor structure 502′, first rear sidestructure 600, a second rear side structure 602, a rear structure 604,and a rear closure structure 606.

The third floor structure 502′ may be disposed proximate variousstructural components, such as the first and second rear side structures602,604 and rear structure 608. In the embodiment shown, the third floorstructure 502′ is configured as variation of the third floor structure502. For example, the third floor structure 502′ may include a pluralityof rear end mating features 610 that may engage the rear structure 604.It should be understood that either third floor structures 502,502′ maybe used in one or more embodiments of the present invention.

The first and second rear side structures 600,602 may be disposed onopposite sides of the vehicle 10. The first and second side structures600,602 may include various features for mating with other vehicle bodystructure components. For example, the first and second side structures600,602 may each include structure mating features 612 that may beintegrally formed with the rear side structures 600,602. The structuremating features 612, if provided, may be disposed along front surfacesof the rear side structures 600,602, respectively. In at least oneembodiment, the structure mating features 612 may engage or interlockwith mating features associated with another zone, such as a rearstructure 440, and may have any suitable configuration as will bediscussed in more detail below. In addition, the first and second sidestructures 600,602 may have mating features that interlock with the rearend structure 604 and/or third floor structure 502′ in one or moreembodiments of the present invention.

The rear structure 604 may include various features for mating withother vehicle body structure components. For example, the rear structure604 may include mating features 614 that engage or interlock with theplurality of rear end mating features 610. In addition, the rearstructure 604 may also include features that facilitate pivotalattachment of the rear closure structure 606.

The rear closure structure 606 may be pivotally disposed on the firstand second rear side structures 600,602 or the rear structure 604 asshown in FIG. 26. The rear closure structure 606 may have any suitableconfiguration, such as a tailgate or side mounted closure.

Referring to FIG. 27, an exemplary embodiment of an interlocking floorassembly 700 is shown. The interlocking floor assembly 700 may include aset of floor structure components. In at least one embodiment, themembers of the set of floor structure components may be castings and maybe made of any suitable material, such as a magnesium or aluminum alloy.In the embodiment shown in FIG. 27, the set of floor structurecomponents includes first, second, and third floor structures254,402,502.

The members of the set of floor structure components may include one ormore sets of mating features that engage or interlock with at least aportion of one other set of mating features to couple the floorstructure components together. These mating features may be integrallyformed. In at least one embodiment, coupling may be accomplished withoutwelding. In addition, the interlocking mating features may permit avehicle to be provided without a frame of welded steel components. Themating features may have any suitable configuration as will be discussedin more detail below.

The first floor structure 254 may include a first set of mating features702 and at least one tunnel. In the embodiment shown, a first tunnel 704is shown, although additional tunnels may be provided in one or moreembodiments of the present invention. For example, additional tunnelsmay be disposed near one or more sides of the first floor structure 254to help provide structural rigidity. Such side tunnels may generallyextend in a longitudinal direction and may have a smaller size than thefirst tunnel 704 to provide a generally flat floor surface near anoccupant seating location. The first set of mating features 702 may bedisposed proximate an end of the first floor structure 254 and may bedisposed proximate the first tunnel 704.

The first tunnel 704 may extend between opposing ends of the first floorstructure 254. In the embodiment shown, the first tunnel 704 isgenerally located near the middle of the first floor structure 254 andmay provide a passage into which various components, such as atransmission, drive shaft, or conduits may extend.

The second floor structure 402 may include second and third sets ofmating features 710,712 and a second tunnel 714. The second set ofmating features 710 may engage or interlock with the first set of matingfeatures 702. The second and third sets of mating features 710,712 maybe disposed proximate opposite ends of the second floor structure 402.In at least one embodiment, at least one of the second and third sets ofmating features 710,712 may be disposed proximate the second tunnel 714.In addition, the second and third sets of mating features 710,712 may bedisposed in different planes. In the embodiment shown in FIG. 27, thesecond set of mating features 710 is generally disposed near a bottomsurface of the second floor structure 402 while the third set of matingfeatures 712 may be disposed near an upper surface of the second floorstructure 402 and above the second set of mating features 710.

The third floor structure 502 may include a fifth set of mating features720. The fifth set of mating features 720 may be disposed proximate anend of the third floor structure 502 and may engage or interlock withthe fourth set of mating features 712. In at least one embodiment, thethird floor structure 502 may include at least a portion of a wheel wellof a vehicle 10.

Referring to FIG. 28, an exemplary interface between the first andsecond tunnels 704,714 is shown. A portion of the first tunnel 704 maybe received by the second tunnel 714 or vice versa. In addition, atleast one of the first and second tunnels 704,714 may include first andsecond sets of tunnel mating features 730,732 and/or a cuff 734. Similarfeatures may be provided with additional tunnels and/or between ifprovided.

The first and second sets of tunnel mating features 730,732 may engageor interlock to help seal or inhibit fluid leakage between the first andsecond floor structures 254,402. The tunnel mating features 730,732 mayhave any suitable configuration. For example, the tunnel mating features730,732 may have any combination of male or female configurations. Inthe embodiment shown, the first set of mating features 730 areconfigured as ribs that extend from an upper surface of the first tunnel704 while the second set of mating features 732 are configured asgrooves that receive the first set of mating features 704 and aredisposed on a lower surface of the second tunnel 714.

At least one cuff 734 may be disposed proximate a tunnel. In theembodiment shown, cuffs 734 are disposed on opposite sides of the firsttunnel 704. The cuffs 734 may receive and/or position the second tunnel714 with respect to the first tunnel 704. In addition, the cuffs 734 maybe curve or extend upwardly to help inhibit fluids from entering betweenthe first and second floor structures 254,402.

The first, second, and/or third floor structures 254,402,502 may includeat least one storage compartment 740. The storage compartments 740 maybe integrally formed in a floor structure and may extend from an uppersurface of an associated floor structure. Storage compartments may beconfigured to receive foldable seats, spare tires, storage bins, or thelike.

Various exemplary embodiments of mating features that may be providedwith vehicle body structure components will now be described in moredetail. In at least one embodiment, similarly configured mating featuresmay mate or interlock together to couple vehicle body structurecomponents together. As such, a vehicle body structure 14 or a portionthereof may be assembled without welding. The mating features may beintegrally formed with a body structure component, such as by casting.In at least one embodiment, a first type of mating feature may beassociated with the engine compartment 20 while a second type of matingfeature may be associated with other vehicle areas, such as thepassenger compartment 22. In at least one other embodiment, a first typeof mating feature may be associated with the engine compartment 20 whilesecond and third types of mating features may be associated with apassenger compartment 22. For example, the passenger compartment 22 mayinclude a second type of mating feature, such as a dovetail matingfeature, for connecting most vehicle body structure components, and athird type of mating feature for connecting panels that at leastpartially define a roof structure to other vehicle body structurecomponents, such as the sides or closure frame structures. In addition,sets of mating features associated with one or more body structurecomponents may be oriented to enable or allow multiple sets of matingfeatures to be engaged simultaneously to facilitate assembly.

The mating features may be configured to interlock and inhibit movementin one or more directions. For example, the mating features may beconfigured to inhibit movement along multiple axes and in multipledirections that differ from the direction in which one mating feature isinserted into another.

Referring to FIG. 29, one embodiment of a set of mating features 750 isshown. Such a mating feature may be provided in any suitable location,such as at an interface between a roof or upper structure and the sidesof the vehicle. The mating feature 750 may include a male portion 752that is received by a female portion 754. The male portion 752 mayinclude one or more enlarged sections 756 that facilitate interlockingor engagement with the female portion 754. The female portion 754 mayinclude one or more openings for receiving the male portion 752. Theopenings may have any suitable configuration. In the embodiment shown, asingle opening 758 is provided; however, the present invention alsocontemplates embodiments having a plurality of enlarged openings thatmay each receive an enlarged section 756. The male portion 752 may beadapted to slide or move relative to the female portion 754 to permitengagement of multiple sets of mating features in a predetermined manneror sequence.

Referring to FIG. 30, one embodiment of a mating feature 800 having adovetail configuration is shown. The mating feature 800 may include maleand female portions 802,804.

The male portion 802 may extend from a vehicle body structure component.In at least one embodiment, the male portion 802 may include a firstsurface 810, a second surface 812, a first joint surface 814, a secondjoint surface 816, and a connecting surface 818.

The male portion 802 may include one or more edges or surfaces thatextend along intersecting planes. In at least one embodiment, the maleportion 802 may have a generally trapezoidal cross section. The maleportion 802 may be tapered in multiple directions. In the embodimentshown in FIG. 30, the male portion 802 is tapered from front to backsuch that the front edge X is longer than the back edge X′. As such, thefirst and second joint surfaces 814,816 may be tapered in a directionthat extends away from the connecting surface 818. In addition, the maleportion 802 may be tapered from top to bottom such that the top edge Yis longer than the bottom edge Y′. As such, the first and second jointsurfaces 814,816 may be tapered in a direction that extends away fromthe first surface 810. Of course, the present invention alsocontemplates embodiments that are not tapered in one or more directionsor tapered in directions that differ from those shown in FIG. 30. Forinstance, the male portion may be tapered from back to front and/orbottom to top in one or more embodiments of the present invention. Anexample of an embodiment in which the male and female portions are nottapered in a direction extending toward the vehicle body structure isshown in FIG. 31. In this embodiment, the first and second jointsurfaces 814′,816′ associated with the male and female portions802′,804′ are not tapered in a direction extending from the connectingsurface 818′ toward an end surface 840′.

The male portion 802 may also include a channel 820. The channel 820 maybe adapted to receive or provide an adhesive to one or more matingfeature surfaces as will be described in more detail below. In at leastone embodiment, the channel 820 may extend between the first and secondsurfaces 810,812. In addition, the channel 820 may narrow or generallyfollow the contour or tapering of one or more surfaces of the maleportion 802. In the embodiment shown in FIG. 30, the channel 820includes first and second pockets 830,832. The first and second pockets830,832 may be are disposed adjacent to each other and may be configuredsuch that the first pocket 830 has a larger volume than the secondpocket 832. In addition, the channel 820 may be disposed proximate anindentation 834 associated with the second surface 812.

The female portion 804 may be configured to receive a male portion 802of a mating feature that is provided with another vehicle body structurecomponent. One or more male portions 802 may be disposed adjacent toeach female portion 804. The female portion 804 may be at leastpartially defined by first and second joint surfaces 814,816 that areassociated with different male portions 802. In addition, the femaleportion 804 may include an end surface 840 and a protrusion 842. The endsurface 840 may extend from or between one or more male portions 802.The protrusion 842 may extend from the end surface 840 and may bereceived by an indentation 834 to help locate and position mating maleand female portions 802,804. In the embodiment shown in FIG. 30, theprotrusion 842 is spaced apart from joint surfaces 814,816 that helpdefine the female portion 804.

A ledge or cap surface 850 may be associated with one or more matingfeatures. The cap surface 850 may be disposed proximate an end of one ormore female portions 804 and may extend from one or more male portions802. For example, the cap surface may extend at least partially acrossan end of one or more female portions 804 as shown on the right side ofFIG. 30. As such, the cap surface 850 may help enclose the matingfeatures, inhibit fluid ingression between adjoining mating featuresurfaces, and may provide improved strength. In at least one embodiment,the protrusion 842 may extend from the cap surface 850.

Referring to FIG. 32, another embodiment of a mating feature having adovetail configuration is shown. In this embodiment, the mating feature800″ may include male and female portions 802″,804″ having generallytrapezoidal cross sections. The male portion 802″ may extend from avehicle body structure component and may be at least partially definedby first and second walls 806″,808″. The first and second walls806″,808″ may include first and second joint surfaces 814″,816″,respectively. The first and second joint surfaces 814″,816″ may betapered relative to each other as previously discussed. A channel 820″may be disposed between the first and second joint surfaces 814″,816″.The walls 806″,808″ may extend from a ledge or cap surface 850″ to helpsupport the walls 806″,808″ to help distribute load forces in one ormore embodiments of the present invention.

Referring to FIGS. 33 and 34, various other exemplary embodiments ofmating features having a dovetail configuration are shown. In FIG. 33,the male and female portions 860,862 have similar configurations. Themale portion 860 may include an extension feature 864 disposed between avehicle body structure component and an enlarged region 866 thatinterlocks with the female portion 862. The enlarged region 866 may haveany suitable configuration. For example, the enlarged region 866 mayextend outwardly from the extension feature 864 in one or moredirections. For instance, in the embodiment shown in FIG. 34, theenlarged region 866′ extends away from the extension feature 864′ andfrom an upper surface 868′ of the male portion 860′ and may include anon-planar surface that engages a female portion 862′ having acompatible configuration.

The mating features previously discussed may be provided in variousarrangements. For example, the mating features may be provided in one ormore rows to provide additional interlocking surfaces and to furtherdistribute load forces. Rows may be provided in any suitable manner. Forexample, in the embodiment shown in FIG. 35, first and second rows870,872 of dovetail mating features are provided. The rows 870,872 maybe positioned such that one or more mating features in each row arealigned with each other. Alternatively, one or more rows 870′,872′ ofmating features may be provided that have at least some mating featuresthat are staggered or offset from those in another row as shown in FIG.36. Rows may be disposed adjacent to each other or spaced apart in oneor more embodiments of the present invention.

An adhesive may be provided to help bond, fill, and/or seal matinginterfaces together. For simplicity, the term adhesive will be used togenerically refer to any material or materials that provide one or moreof the aforementioned functions. In at least one embodiment, a heatcatalyzed mastic material may be employed to fill any gaps betweenmating surfaces. The adhesive may be provided in any suitable manner.For example, the adhesive may be applied to one or more surfaces of amating feature before, during or after the mating features areinterlocked. In at least one embodiment, the adhesive may be providedvia a channel 820 as previously discussed. In addition, the adhesive mayfacilitate repair or replacement of vehicle body structure components.For example, in at least one embodiment the adhesive may be softenedthrough the application of heat to permit components to be separated.

The vehicle body structure 10 may be assembled by interlocking orengaging mating features in any suitable manner. In at least oneembodiment, a subset of vehicle body structure components may beassembled together to form subassemblies that may then be assembled tocreate a vehicle body structure. For example, vehicle body structurecomponents may be assembled to create the upper portion 18 and lowerportion 20, then the upper and lower portions 18,20 may be assembledtogether to create the vehicle body structure 10. In at least oneembodiment, the upper portion 18 may be attached to the lower portion 20in any suitable manner, such as by engaging or interlocking additionalmating features or with one or more fasteners. In other embodiments,subassemblies may be provided by assembling roof, sides, or zones ofbody structure components together, and then assembling thesubassemblies to create the vehicle body structure 10.

Assembling a vehicle body structure with interlocking components mayreduce or eliminate equipment and labor associated with body panelstamping and body shop operations in which multiple sheet metalcomponents are welded together to create a vehicle body. In addition,interlocking components may enable a vehicle assembly plant to constructmultiple vehicle body styles on a common assembly line. For example,multiple vehicle types like those shown in FIGS. 37 a-37 d may share oneor more vehicle body structure components. Moreover, an interlockingvehicle body structure may permit vehicles to be reconfigured intoanother vehicle style or type. For instance, a vehicle make bereconfigured from a sedan configuration 880 to a station wagonconfiguration 882, sport utility/crossover vehicle configuration 884, ora pickup truck configuration 886 by replacing select third and fourthzone vehicle body structure components and body panels. The presentinvention also contemplates that one or more components in any zone maybe replaced or reused to provide additional vehicles or vehicleconfigurations.

Referring to FIG. 38, an exemplary body panel 900 is shown. The bodypanel 900 may be configured to cover at least a portion of at least onevehicle body structure component. For example, a plurality of bodypanels may be disposed on the upper portion 18 of the vehicle bodystructure 14 and may form an exterior surface of the vehicle 10. Thebody panels may have any suitable configuration and may be made of anysuitable material. For instance, one or more body panels may be made ofa polymeric material and may be configured to flex to facilitatemounting and/or removal. In addition, the body panels 900 may beprovided with one or more molded-in colors to reduce or eliminatepainting or coating of a body panel and reduce associated labor,equipment, and facility costs.

Each body panel 900 may include a first surface 902 and a second surface904 disposed opposite the first surface 902. The first surface 902 mayform an exterior vehicle surface. The second surface 904 may face towardone or more vehicle body structure components. The second surface 904may include one or more stiffening features 906 that help the body panel900 retain a desired shape and may provide additional support byengaging a vehicle body structure component. In addition, each bodypanel 900 may include at least one mating feature 908. The matingfeatures 908 may be disposed proximate any suitable surface. In at leastone embodiment, the stiffening features 906 and mating features 908 maybe integrally formed with the body panel 900 and may extend from or intothe second surface 904.

The mating features 908 may have any suitable configuration, such as amale configuration, female configuration, or combinations thereof. Inthe embodiment shown in FIG. 38, a plurality of mating features 908extend from the second surface 904 and are disposed near a perimeter ofthe body panel 900. As such, one or more mating features 908 may alsoprovide localized stiffening of the body panel 900. In at least oneembodiment, a mating feature may in a generally continuous mannerrelative to one or more sides of the body panel. For instance, a matingfeature 908′ may extend into or away from a body panel 900′ and mayextend in a ringlike manner around a portion of the body panel 900′ asshown in FIG. 39 to provide a seal that inhibits moisture from passingbetween the body panel 900′ and at least one associated vehicle bodystructure component. In at least one embodiment, the mating feature 908′may also include a second ring 908″ that can accommodate an associatedbody mating feature having a male and/or a female configuration.

Referring again to FIG. 38, the body panel 900 may include a set ofhinge covers 920. The set of hinge covers 920 may be disposed along aside of the body panel 900 any may be configured to at least partiallyconceal a closure hinge area. The members of the set of hinge covers 920may be spaced apart from each other to create a gap 922. A portion of ahinge cover disposed on another body panel may extend into the gap 922as is best shown in FIG. 1.

One or more members of the set of hinge covers 920 may include at leastone flange 924 that extends away from the second surface 904 and furtherfacilitates mounting of the body panel 900. The flange 924 may includean aperture 926 through which the hinge pin 340 of a closure hinge mayextend. The flange 924 may be disposed proximate an associated hingeportion, such as hinge portions 298 or 320, when the body panel isassembled to the vehicle body structure 14. For example, the flange 924may be disposed proximate a pocket 328 of a hinge portion 298,320 asrepresented in FIG. 40. In at least one embodiment, a plurality offlanges 924 may extend from a hinge cover 920 and may be disposedproximate opposing walls that at least partially define the pocket 328as shown in FIG. 41.

Referring to FIG. 42, a magnified view of an exemplary connectionbetween a body panel 900 and a vehicle body structure component isshown. Reference number 930 will be used to generically refer to avehicle body structure component since multiple body structurecomponents may engage at least one body panel.

In the embodiment shown, the body panel 900 includes a body panel matingfeature 908 having a male configuration and the vehicle body structurecomponent 930 includes a body structure mating feature 932 having afemale configuration. The body structure mating feature 932 maypartially or completely extend into the body structure component in oneor more embodiments of the present invention.

The body panel mating feature 908 may protrude from the body panel 900and may include a hole 934. The body structure mating feature 932 may beconfigured as a groove having at least one hole 938 that may becoaxially aligned with hole 934. A fastener 940 may extend through atleast one hole 938 in the body structure component 930 and the hole 934in the body panel 900 to inhibit removal of the body panel 900.Installation of the fastener 940 may be facilitated by an openingprovided in a vehicle body structure component 930. For instance, thefastener 940 may be inserted through an opening that faces the engine orpassenger compartment 22,24 rather than through an opening in the bodypanel 900 in one or more embodiments of the present invention. Suchembodiments may inhibit unintended or unauthorized removal of a bodypanel since access to the interior of the vehicle may be needed toaccess a fastener.

Referring to FIGS. 43 and 44, additional exemplary connections between abody panel and a vehicle body structure component is shown. In theembodiment shown in FIG. 43, the body panel 900 includes a body panelmating feature 908′ having a female configuration and the vehicle bodystructure component 930 includes a body structure mating feature 932′having a male configuration. A fastener 940 may extend through at leastone hole 934 in the body panel 900 and the hole 938 in the bodystructure component 930 to inhibit removal of the body panel 900. In theembodiment shown in FIG. 44, the fastener 940′ may extends through ahole in the body structure mating feature 932″ and may engage the bodypanel mating feature 908″ to couple or otherwise inhibit removal of thebody panel 900.

Referring to FIGS. 45 and 46, additional views of a vehicle body panelare shown. The body panel 900 may include a flexible rim 950 may atleast partially define a perimeter surface of the body panel 900 and maygenerally extend from a body panel mating feature 932,932′. In at leastone embodiment, the flexible rim 950 may include an end portion 952 thatextends toward the vehicle body structure 14.

The body panel 900 may be adapted to accommodate expansion and/orcontraction of one or more vehicle surfaces or components. For example,the flexible rim 950 may extend toward and contact a vehicle bodycomponent, such as a window 954, and may flex to accommodate movementand/or help the body panel 900 maintain contact with the window 954 toinhibit moisture ingression. In addition, a gap 956 may be disposed thebody panel mating feature 932,932′ and the window 954 to accommodateexpansion and contraction. The gap 956 may also disposed adjacent to anedging member 958 that is associated with the vehicle body component.The edging member 958 may include a window groove 960 for receiving thewindow 954, which may be configured to guide movement of the window 954.The edging member 958 may be attached to another component, such as abody structure component 930 in any suitable manner.

The connection structures and techniques described above may permit abody panel to be assembled to a vehicle body structure free of welding.Moreover, the connection structures and techniques may provideflexibility in vehicle assembly processes as body panels may beassembled to one or more body structure components either before orafter assembly of a portion of the vehicle body structure 14. Suchflexibility may help improve equipment and assembly plant utilizationand provide associated cost advantages. In addition, the connectionstructures and techniques may permit a body panel to be easily removedand replaced, thereby enabling changes to a vehicle color orconfiguration after initial assembly. For example, vehicle purchasers ordealers may remove and replace body panels to provide a differentvehicle appearance or accommodate the installation of different vehiclebody structure components. In addition, in at least one embodiment ofthe present invention, servicing and/or replacement of vehiclecomponents may be improved. For example, parts that may be more likelyto be damaged may be configured to be easily repaired and/or accessed.

While the best mode for carrying out the invention has been described indetail, those familiar with the art to which this invention relates willrecognize various alternative designs and embodiments for practicing theinvention as defined by the following claims.

1. A method of manufacturing a vehicle, comprising: providing a set ofcast vehicle body structure components, each member of the set of castvehicle body structure components having a mating feature; andassembling each member of the set of cast vehicle body structurecomponents to at least one other member of the set by interlocking themating features.
 2. The method of claim 1 wherein the step of assemblingeach member of the set of cast vehicle body structure components furthercomprises providing an adhesive proximate at least one mating feature.3. The method of claim 2 wherein the adhesive is provided via a channelthat is associated with the at least one mating feature.
 4. The methodof claim 3 wherein the at least one mating feature has a dovetailconfiguration and the channel is a through hole that extends through theat least one mating feature.
 5. The method of claim 1 wherein a floorportion and an upper portion are assembled from the set of cast vehiclebody structure components and the upper portion is assembled to thefloor portion.
 6. The method of claim 1 wherein at least some of themating features have a dovetail configuration.
 7. The method of claim 1wherein the set of cast vehicle body structure components are assembledfree of welding.
 8. The method of claim 1 wherein at least a portion ofthe mating features have a male portion and a female portion thatreceives a male portion of another member of the set.
 9. The method ofclaim 1 wherein at least one member of the set includes a mating featureconfigured as a tenon and at least one other member of the set includesa mating feature configured as a mortise that receives the tenon.
 10. Amethod of manufacturing a vehicle, comprising: providing a set ofvehicle body structure components; selecting a first subset from the setof vehicle body structure components; selecting a second subset from theset of vehicle body structure components; assembling a floor portion byinterlocking each member of the first subset to another member of thefirst subset; assembling an upper portion by engaging each member of thesecond subset to another member of the second subset; and assembling theupper portion to the floor portion.
 11. The method of claim 10 whereinthe step of assembling the upper portion further comprises interlockinga portion of the second subset to create a passenger compartment. 12.The method of claim 11 wherein the portion of the second subset thatcreates the passenger compartment is assembled by interlocking dovetailmating features.
 13. The method of claim 12 wherein the step ofassembling the upper portion further comprises providing an adhesive tothe interlocking dovetail mating features.
 14. The method of claim 13wherein the adhesive is provided through a channel that is provided withat least one of the interlocking dovetail mating features.
 15. Themethod of claim 10 wherein at least some of the members of the set ofvehicle body structure components are castings made of a magnesiumalloy.
 16. A method of manufacturing a vehicle, comprising: providingfirst and second sets of castings; assembling a floor portion byinterlocking the members of the first set of castings; assembling anupper portion by interlocking the members of the second set of castingswithout welding; and assembling the upper portion to the floor portion.17. The method of claim 16 wherein each member of the first set ofcastings further comprises a plurality of dovetail mating features,wherein the plurality of dovetail mating features of a first member ofthe set of castings interlocks with the plurality of dovetail matingfeatures of another member of the set of castings.
 18. The method ofclaim 16 wherein at least one member of the second set of castingsfurther comprises first and second types of mating features that differfrom each other.
 19. The method of claim 18 wherein the first type ofmating feature is employed to interlock members of the second set ofcastings that at least partially define a passenger compartment.
 20. Themethod of claim 18 wherein the second type of mating feature is employedto interlock members of the second set of castings that at leastpartially define an engine compartment.